Stellar Flex36 User Manual
®
OWNER’S MANUAL
Safety, Installation, Maintenance, and Operation
Stellar Flex36 Hooklift
Models
60-8
84-10
108-12
120-14
Subject to Change without Notification.
© 2007 Stellar Industries, Inc.
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com
Manual Part No. 35551
Last Revision: 10/03/07
Flex36 Hooklift Manual Revisions
Date of Revision
August 27, 2007
Section Revised
Chapter 6 - Installation
Description of Revision
Updated Reservoir Assembly Drawing (PN 35883) to reflect
engineering changes.
Table of Contents
Table of Contents i
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Stellar Flex Hooklift Nomenclature . . . . . . .iv
Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . .1
General Safety . . . . . . . . . . . . . . . . . . . . . . .1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . .1
Maintenance Safety . . . . . . . . . . . . . . . . . .1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Load Safety . . . . . . . . . . . . . . . . . . . . . . . . . .2
Environment . . . . . . . . . . . . . . . . . . . . . . . . . .2
Chapter 2 - Operation . . . . . . . . . . . . . . . . . . .3
Job-Site Set-Up . . . . . . . . . . . . . . . . . . . . . . .3
Operator Requirements . . . . . . . . . . . . . . . .3
Operator Conduct . . . . . . . . . . . . . . . . . . . .3
Hooklift Controls . . . . . . . . . . . . . . . . . . . . . .4
Operation Overview . . . . . . . . . . . . . . . . . . .4
Unloading Operation . . . . . . . . . . . . . . . . . .5
Loading Operation . . . . . . . . . . . . . . . . . . . .6
Dumping Operation . . . . . . . . . . . . . . . . . . .7
Chapter 3 - Maintenance . . . . . . . . . . . . . . . .9
Maintenance Procedures . . . . . . . . . . . . . .9
Periodic Inspection . . . . . . . . . . . . . . . . .9
Daily Inspection
Monthly Inspection . . . . . . . . . . . . . . . . .9
General Service . . . . . . . . . . . . . . . . . . . .9
Choice Lubricants for DX Bearings . . . . . .10
Chapter 4 - Specifications . . . . . . . . . . . . . .11
Stellar Flex36 Model 60-8
Hydraulic Hooklift Specifications . . . . .12
Stellar Flex36 Model 84-10
Hydraulic Hooklift Specifications
Stellar Flex36 Model 108-12
Hydraulic Hooklift Specifications . . . . .14
Stellar Flex36 Model 120-14
Hydraulic Hooklift Specifications . . . . .15
Chapter 5 - Decals . . . . . . . . . . . . . . . . . . . .17
Decals of Note . . . . . . . . . . . . . . . . . . . . . .17
Decal Kit Placement - PN 35559 . . . . . . . .18
Chapter 6 - Installation . . . . . . . . . . . . . . . . .19
Basic Installation Overview
Installation Steps - Basic Guidelines
Mounting Kit (Model 60-8) - PN 33320 . . .22
Mounting Kit (Models 84-10, 108-12,
120-14) - PN 23700
Rotary Valve
(All Models) - PN 37741 . . . . . . . . . . . . .24
Reservoir Assembly - PN 35883 . . . . . . . . .25
Setting System Relief Pressure . . . . . . . . .26
Installation Instructions for the
. . . . . . . . . . . . . . . . . . . .9
. . . . .
. . . . . . . . . . . .
. . . . .
. . . . . . . . . . . . . . . . .
13
19
20
23
Power Beyond VDM8 Valve . . . . . . . . .28
Port Side Relief Installation . . . . . . . . . . . . .29
Controller Assembly - PN 38841 . . . . . . . .30
Dump Light Kit Installation . . . . . . . . . . . . .31
Hydraulic Schematic
(Model 60-8) - PN 34616 . . . . . . . . . . . .32
Hydraulic Schematic
(Model 84-10)- PN 34617 . . . . . . . . . . . .33
Hydraulic Schematic
(Model 108-12) - PN 34618 . . . . . . . . . .34
Hydraulic Schematic
(Model 120-14)- PN 34619 . . . . . . . . . . .35
Subframe Model 60-8 . . . . . . . . . . . . . . . . .36
Subframe Model 84-10 . . . . . . . . . . . . . . . .37
Subframe Model 108-12 . . . . . . . . . . . . . . .38
Subframe Model 120-14 . . . . . . . . . . . . . . .39
Chapter 7 - Assembly Drawings . . . . . . . . . .41
Base Assembly (60-8) - PN 31823 . . . . . . .41
Base Assembly (84-10) - PN 33337 . . . . . .42
Base Assembly (108-12) - PN 34245 . . . . .43
Base Assembly (120-14) - PN 33419 . . . . .44
Dump Assembly (60-8) - PN 31824
Dump Assembly (84-10) - PN 33339 . . . . .46
Dump Assembly (108-12) - PN 34247 . . . .47
Dump Assembly (120-14) - PN 33417 . . . .48
Secondary Assembly
(60-8) - PN 33047 . . . . . . . . . . . . . . . . . .49
Secondary Assembly
(84-10) - PN 33341 . . . . . . . . . . . . . . . . .50
Secondary Assembly
(108-12) - PN 34249 . . . . . . . . . . . . . . . .51
Secondary Assembly
(120-14) - PN 33415 . . . . . . . . . . . . . . . .52
Tilt Assembly
(All Flex36 Models) - PN 33049 . . . . . . .53
Tilt Assembly
(Optional Tall Tilt) - PN 35032 . . . . . . . .54
Tilt Cylinder Assembly
(All Flex36 Models) - PN 23460
Main Cylinder Assembly
(60-8) - PN 27116 . . . . . . . . . . . . . . . . . .56
Main Cylinder Assembly
(84-10)- PN 33404
Main Cylinder Assembly
(108-12, 120-14)- PN 33462 . . . . . . . . . .58
Chapter 8 - Replacement Parts . . . . . . . . . .59
Chapter 9 - Troubleshooting . . . . . . . . . . . . .61
Warranty Information . . . . . . . . . . . . . . . . . . .62
. . . . . . . . . . . . . . . . . .
. . . . . .45
. . . . . . .
55
57
ii Flex36 Owner’s Manual
AN OVERVIEW TO OWNER, OPERATOR AND
SERVICE PERSONNEL ABOUT SAFETY
As the owner or employer, it is your responsibility to instruct the operator in the safe operation of this equipment and to provide the operator with properly maintained equipment.
FAILURE TO READ THIS MANUAL BY ANYONE WHO WILL OPERATE, SERVICE, OR WORK
AROUND THIS HOOKLIFT IS A MISUSE OF THE EQUIPMENT. DEATH OR SERIOUS INJURY WILL
RESULT FROM IMPROPER USE OR MAINTENANCE OF THIS MACHINE.
Occupational safety is a prime concern of Stellar Industries in the design and production
of this hooklift. Our goal in writing this manual was the safety of the operator and others
who work around this equipment.
It is your responsibility to know the specific requirements, governmental regulations, precautions and work hazards that exist in the operation and maintenance of this hooklift.
You shall make these available and known to all personnel working with and around the
equipment, so that all of you will take the necessary and requir
FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.
ed safety precautions.
It is also your responsibility to operate and maintain your hooklift with caution, skill, and
good judgment. Following the recognized safety procedures will help you avoid accidents. Modification to any part of his hooklift can create a safety hazard and therefore
shall not be made without the manufacturer’s written approval. Use only factory
approved accessories, options, and parts on this equipment. The rebuilding or remounting
of this equipment requires the mounting procedures and retesting to be in accordance
with factory instructions. Safety covers and devices must remain installed and maintained
in proper working condition. Safety decals must be maintained, be completely legible,
and be properly located. If safety covers, devices, or decals are missing, they must be
replaced with the proper designated Stellar part.
Be capable, careful, and concerned! Make safety your everyday business!
Attention!
According to Federal Law (49 cfr part 571),
each final-stage manufacturer shall complete the vehicle in such a manner that it
conforms to the standar
date of manufacture of the incomplete
vehicle, the date of final completion, or a
date between those two dates. This requirement shall, however, be superseded by any
conflicting provisions of a standard that
applies by its terms to vehicles manufactured in two or more stages.
Therefore, the installer of Stellar hooklifts is
considered one of the manufacturers of the
vehicle. As such a manufacturer
ds in ef
fect on the
, the
installer is responsible for compliance with
all applicable federal and state regulations.
They are required to certify that the vehicle
is in compliance with the Federal Motor
Vehicle Safety Standards and other regulations issued under the National Traffic and
Motor Vehicle Safety Act.
ence the Code of Federal
Please r
Regulations, title 49 - Transportation,
Volume 5 (400-999), for further information,
or visit
www.gpoaccess.gov/nara/index.html for
the full text of Code of Federal Regulations.
efer
Introduction
Introduction iii
Stellar Hooklifts are designed to provide safe
and dependable service for a variety of
operations. With proper use and
maintenance, these hooklifts will operate at
peak performance for many years.
To promote this longevity, carefully study the
information contained in this manual before
putting the equipment into service. Though
it is not intended to be a training manual for
beginners, this manual should provide solid
guidelines for the safe and proper usage of
the hooklift.
Once you feel comfortable with the
material contained in this manual, strive to
cise your knowledge as you safely
exer
operate and maintain the hooklift. This
process is vital to the proper use of the unit.
A few notes on this manual:
A copy of this manual is provided with every
hooklift and shall remain with the hooklift at
all times. Information contained within this
manual does not cover all maintenance,
operating, or repair instructions pertinent to
all possible situations.
Please be awar
manual contain information pertaining to
e that some sections of this
Stellar manufactured hooklifts in general
and may or may not apply to your specific
model.
This manual is not binding. Stellar Industries,
Inc. reserves the right to change, at any
time, any or all of the items, components,
and parts deemed necessary for product
improvement or commercial/production
purposes. This right is kept with no
requirement or obligation for immediate
mandatory updating of this manual.
In closing:
If more information is required or technical
assistance is needed, or if you feel that any
part of this manual is unclear or incorrect,
please contact the Stellar Customer Service
Department by phone at 800-321-3741 or
email at service@stellarindustries.com.
ATTENTION
Failure to adhere to the
instructions could result in
property damage or even serious
bodily injury to the operator or
others close to the hooklift.
For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at
800-321-3741
Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST
Or email at the following addresses:
Technical Questions, and Information service@stellarindustries.com
Order Parts parts@stellarindustries.com
Warranty Information warranty@stellarindustries.com
iv Flex36 Owner’s Manual
HOOKLIFT
BASE
DUMP
SECONDARY
TILT
Stellar Flex Hooklift Nomenclature
The Stellar Flex is a hydraulic, body-loading device when mounted on a truck chassis.
When mounted, the Stellar Flex can handle a variety of bodies ranging from flatbeds to
recycling containers to dump bodies.
Two independently controlled cylinders operate all the functions of the Stellar Flex. By
varying the cylinder operation, the Stellar Flex can be used to dump or unload a body.
The Stellar Flex consists of four basic parts: The base, dump, secondary, and tilt sections.
Familiarize yourself with the various components of this hooklift and the names of those
components. Knowing the proper terminology is necessary to get full benefit from this
manual
Chapter 1 - Safety
Safety 1
Please Read the Following Carefully! This
portion of the manual contains information
regarding all Stellar manufactured hooklifts.
Some items contained within this chapter
may not apply to your specific equipment.
Safety should be the number one thought
on every operator’s mind. Three factors
should exist for safe operation: a qualified
operator, well-maintained equipment, and
the proper use of this equipment. The
following information should be read and
understood completely by everyone
working with or near the hooklift before
putting the unit into operation.
Please take note that Stellar Industries, Inc.
is not liable for accidents incurred by the
hooklift because of non-fulfillment from the
operator’s side of current rules, laws, and
regulations.
General Safety
It is the responsibility of the owner to instruct
the operator in the safe operation of your
equipment and to provide the operator with
properly maintained equipment.
anti-noise headphones, protective glasses,
breathing apparatus, and reflective jackets.
Consult your employer regarding current
safety regulations and accident-prevention
equipment.
Do not wear rings, wristwatch, jewelry, loosefitting or hanging clothing such as ties, torn
garments, scarves, unbuttoned jackets or
unzipped overalls, which could get caught
up in the moving parts of the hooklift.
Keep a first-aid box and a fire extinguisher
readily available on the truck. Regularly
check to make sure the fire extinguisher is
fully charged and the first-aid kit is stocked.
Do not use controls and hoses as handholds.
These parts move and cannot provide stable support.
Do not allow unauthorized personnel or
equipment to enter within 10 feet of hooklift
operating area.
Never allow anyone to ride the hooklift or
load.
Trainees or untrained persons shall be under
the direct supervision of qualified persons.
Do not operate equipment under the
adverse influence of alcohol, drugs, or medication.
Read all Danger and Caution decals on the
equipment and understand their meaning.
Personal Safety
Keep clear of all moving parts.
Always wear the pr
devices.
Always wear appr
clothing such as: protective helmets, antislip shoes with steel toes, protective gloves,
escribed personal safety
oved accident-prevention
Maintenance Safety
Never modify or alter any of the equipment,
whether mechanical, electrical, or hydraulic,
without Stellar Industries’ approval.
Do not perform any maintenance or repair
work on the hooklift unless authorized and
trained to do so.
Release system pressure before attempting
to make adjustments or repairs.
Do not attempt service or repair when PTO is
engaged.
Decals are considered safety equipment.
They must be maintained, as would other
safety devices. Do not remove any decals.
2 Flex36 Owner’s Manual
Replace any decals that are missing, damaged, or not
legible.
The safety instruction plates, notices, load
charts and any other sticker applied to the
hooklift must be kept legible and in good
condition. If necessary, replace them.
Keep all surfaces of the hooklift free of oil
and grease to avoid slippery surfaces and
aid in
inspections.
Stability
Know the hooklift components and their
capabilities and limitations. Overloading the
hooklift may result in serious damage of self,
others, equipment or the surroundings.
Never exceed manufacturer’s load ratings.
These ratings are based on the machine’s
hydraulic, mechanical, and structural design
rather than stability.
Load Safety
Full rated dump capacity assumes load will
decrease as dump angle increases. Do not
take full rated capacity to full dump angle
without some unloading of weight as it may
cause damage to the chassis and/or the
hooklift.
Move the control lever slow and smooth for
steady oil flow.
Avoid jerky or sudden movement of the controls.
weight can be lifted.
Keep everyone clear when loading, unloading, and dumping.
Do not push on fixed objects or bodies without rollers with the hooklift.
Do not permit loose objects on the hooklift.
Use a qualified person to assist in loading
when the load is not visible to the operator.
Do not leave hooklift unattended with suspended load.
Take care when operating in areas supported by vehicle tires, because of the cushioning effect of springs and tires.
Never use the drivetrain of the chassis to
assist the hydraulics in loading
Environment
Do not operate the hooklift during electrical
storms.
In extreme cold, allow adequate time to
warm the truck before engaging the PTO.
Do not rev the truck engine and over speed
the hydraulic pumps as permanent damage
to the pumps may occur. Follow the vehicle
owner’s manual regarding operating the
vehicle in such adverse conditions.
In extreme cold, operate the controls slowly
to allow for viscosity changes.
Be constantly aware of the hooklift position
when operating the controls.
Do not attempt to lift fixed loads.
Know the weight of your load to avoid overloading the equipment.
Deduct the weight of the body from the
maximum load rating to determine how
much
ATTENTION
Stellar Industries, Inc. is not liable
for accidents incurred by the
hooklift because of the
operator’s non-fulfillment of
current rules, laws and
regulations.
Chapter 2 - Operation
Operation 3
Job-Site Set-Up
Thoroughly plan the lift before positioning
the vehicle. Consider the following:
1. The vehicle should be positioned in an
area free from overhead obstructions to
eliminate the need for repositioning.
2. Position the vehicle so that it is impossible
for any portion of the equipment to come
within the minimum required safe distance
of any power line. Maintain a clearance
of at least 10 feet between any part of
the hooklift, load line, or load, and any
electrical line or apparatus carrying up to
50,000 volts. One foot additional clearance is required for every additional
30,000 volts or less. Remember to allow
for winds that cause power lines to sway.
It is recommended that a signal person
be used when the vehicle is set-up near
power lines.
3. The vehicle should also be positioned on
a firm and level surface that will provide
adequate support for the body.
Operator Requirements
Operation is limited to the following people:
A. Qualified individual.
B. Trainees under direct supervision of the
qualified individual.
C. Test or maintenance individual.
D. Hooklift Inspector.
Operators must:
A. Demonstrate the ability to understand
all decals, the owner’s manual, and any
other information required for safe operation of the hooklift.
B. Be able to demonstrate the ability to
safely control the hooklift.
C. Know all safety r
D. Be responsible for maintenance require-
ments.
E. Understand and be fully capable of
implementing all emergency proce-
dures.
F. Understand the operating procedures as
outlined by this manual, Ansi B30.5 and
Federal/State Laws.
egulations.
4. The parking brake must be removed to
allow the truck to roll under the body
while loading.
CAUTION
1.
When loading and unloading
bodies, the tilt cylinder must be
fully extended before operating
the lift cylinder to prevent
damage to the latch systems.
2. When the PTO is engaged, do
not run the engine over 1400
RPM.
3. Do not hold the brakes while
performing operations.
Operator Conduct
1. Operators will not engage in any operation that would cause them to divert
attention away fr
the hooklift.
2. Operators are responsible for all opera
tions under their direct control.
3. Operators will not leave a suspended
load unattended.
4. Operators will be familiar with the equipment and the maintenance required for
oper care.
pr
om the operation of
-
4 Flex36 Owner’s Manual
Hooklift Controls
1. Be familiar with the sequence and operation of the hooklift controls.
2. Each individual hooklift function should
have control function decals. Replace
them immediately if they are missing or
illegible.
3. Keep hands, feet and control levers free
from mud, grease and oil.
4. Be familiar with the control levers and
how they operate before attempting to
operate the hooklift.
5. Be prepared before beginning operation of the hooklift:
• All pr
•
• Be sure all safety devices provided are
• Be prepared for all situations. Keep
• Be sure all regular maintenance has
• Visually inspect all aspects of the
• Check for fluid leaks.
otective guards must be in place.
Be aware of the surroundings: low
branches, power lines, unstable
ground.
in place and in good operating condition.
fire extinguisher and first aid kit near.
been performed.
hooklift for physical damage.
Operation Overview
Unloading Operation
. Stop the truck at the location you wish to unload.
1
2. Put the truck in neutral and engage the PTO.
Run RPM as needed.
3. Locate the black control lever labeled tilt.
4. Pull the tilt lever until the cylinder is fully extended, thus releasing tabs.
5. Locate the red lever labeled lift.
6. Pull lift lever until the body is on the ground and
can be detached. Return the hooklift to the
stored position and disengage the PTO.
Loading Operation
1. Position the truck in line with the body you intent
to pick up.
2. Engage the hook to the body by maneuvering
the hooklift with the red(lift) lever. Run RPM as
needed.
3. Push the red(lift) lever until the main cylinder is
fully retracted.
4. Push the black(tilt) lever until the tilt is fully
extended.
5. Disengage the PTO.
NOTE: The controller assembly pictured in this
chapter may differ from model to model.
Dumping Operation
1. Stop the truck at the location you wish to dump
the load.
2. Put the truck in neutral and engage the PTO.
Run RPM as needed.
3. Locate the red lever labeled lift.
4. Pull the lever to dump the body.
5.Wait until dumping is complete, then push the
red(lift) lever until the main cylinder fully retracts.
6. Disengage the PTO.
Unloading Operation
5Operation 5
1. Stop the truck at the location you wish to unload.
3. Locate the black control lever labeled tilt.
2. Put the truck in neutral and engage the PTO.
Run RPM as needed.
4. Pull the tilt lever until the cylinder is
fully extended, thus releasing tabs.
5. Locate the r
ed lever labeled lift.
6. Pull lift lever until the body is on the ground and
can be detached. Return the hooklift to the
stored position and disengage the PTO.
6 Flex36 Owner’s Manual
Loading Operation
1. Position the truck in line with the
body you intent to pick up.
3. Push the red(lift) lever until the
main cylinder is fully retracted.
2. Engage the hook to the body by maneuvering
the hooklift with the red(lift) lever.
Run RPM as needed.
4. Push the black(tilt) lever until
the tilt is fully retracted.
5. Disengage the PTO.
Dumping Operation
7Operation 7
1. Stop the truck at the location
you wish to dump the load.
3. Locate the red lever labeled lift.
2. Put the truck in neutral and engage the PTO.
Run RPM as needed.
4. Pull the lift lever to dump the body.
5. Wait until dumping is complete, then push the
ed(lift) lever until the main cylinder fully r
r
etracts.
6. Disengage the PTO.
8 Flex36 Owner’s Manual
Chapter 3 - Maintenance
9Maintenance 9
Please read the following before performing any
m
aintenance on the hooklift.
1. Only authorized service personnel are to perform
maintenance on the hooklift.
2. Disengage the PTO before any service or repair is
performed.
3. Do not disconnect hydraulic hoses while there is
still pressure in those components.
4. Before disconnecting hydraulic components,
shut off the engine, release any air pressure on
the hydraulic reservoir, and move control levers
repeatedly through their operating positions to
relieve all pressures.
Keep the hooklift clean and free from grease
5.
build-up, oil and dirt to prevent slippery conditions.
6. Perform all safety and maintenance checks
before each period of use.
7. Replace parts with Stellar Industries, Inc.
approved parts only.
8. Immediately repair or have repaired any components found to be inadequate.
Maintenance Procedures
1. Position the hooklift where it will be out of the way of
other operations or vehicles in the area.
2. Place all controls in the off position and secure operating features from inadvertent motion.
3. Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components.
4. Label or tag parts when disassembling.
Periodic Inspection
Periodic Inspection should occur while the hooklift is in
use. For the duration of the usage, inspect the hooklift
for all of the following:
1. Loose bolts and fasteners.
2. All pins, bushings, shafts, and gears for wear, cracks,
or distortion to include all pivot points, and bushings.
e.
Hydraulic systems for pr
3.
4. Main frame mount bolts.
5. Cylinders for:
A. Damaged rods.
B. Dented barrels.
C. Drift fr
D. Leaks at rod seals or holding valves.
6. PTO and hydraulic pump(s) for leaks.
Hydraulic hose and tubing for evidence of damage
7.
such as blistering, crushing, or abrasion.
esence of this owner’s manual.
8. Pr
Daily Inspection
Daily Inspection should occur each day before the
hooklift is put into use. Each day, inspect the hooklift for
all of the following:
om oil leaking inter
oper operating pr
nally.
essur
1. Hydraulic oil level.
2. Loose parts or damage to structures or weld.
3. Cylinder movement due to leakage.
4
. Hoses for evidence of oil leaks.
5. Controls for malfunction or adjustment.
6. Parking brake operation.
7. All securing hardware such as cotter pins, snap rings,
h
airpins, and pin keepers for proper installation.
8. All safety covers for proper installation.
9. Cylinder holding valves for proper operation.
10. Equipment for missing, illegible, or defaced operat-
ing decals and safety signs.
Monthly Inspection
Monthly Inspection should occur at the beginning of
every work month. Each month, inspect the hooklift for
all of the following:
1. Frame bolt tightness - turn barrel nuts and mounting
bolts during the first month of operation on new
machines and then quarterly thereafter.
2. Cylinders and valves for leaks.
3. Lubrication.
4. Tilt hook for cracks.
5. Structural weldments for bends, cracks, or breaks.
6. All pins and keepers for proper installation.
7. All control, safety, and capacity placards for read-
ability and secure attachment.
8. Inspect all electrical wires and connections for worn,
cut, or deteriorated insulation and bare wire.
Replace or repair wires as required.
10. Lubrication of all points requiring lubrication.
General Service
The following general suggestions should be helpful in
analyzing and servicing your hooklift. Using the following
systematic approach should be helpful in finding and
fixing problems:
1. Deter
2. List and record possible causes.
3. Devise checks.
4. Conduct checks in a logical order to determine the
5. Consider the remaining service life of components
6. Make the necessary repair.
7. Recheck to ensur
8. Functionally test the new part in its system.
mine the pr
cause.
against the cost of parts and labor necessary to
replace them.
oblem.
e that nothing has been overlooked.
Cleanliness
An important item in preserving the
long life of the hooklift is keeping dirt,
grime, and corrosive material out of
the working parts. Thoroughly wash
and grease the hooklift periodically.
10 Flex36 Owner’s Manual
Choice Lubricants for DX Bearings
Type of Grease Description
Greases Recommended
Premium Quality
Multi-Purpose
Multi-Purpose Calcium Based, for General Automotive and Industrial Use
Anti-Friction Bearing Calcium Based with EP Additives
Extreme Pressure (EP) Lithium Based with EP Additives
High Temperature Modified Sodium Based, High Drop Point
Transmission Semi-Fluid, Calcium Based
Molybdenum Filled Lithium Based with 2% Molybdenum Disulfide
Graphite Filled Sodium Based with 2% Graphite
Block Grease Sodium Based Solid Grease
White Grease Aluminum Complex Based with Anti-Oxidant & Rust
Silicone Lithium Based with Silicone Oil Lubricant
Stabilized, Anti-Oxidant Lithium Base
Lithium Base with 3% Molybdenum Disulfide
High Drop Point
Calcium Grease, Water Stabilized, High Drop Point
Lithium Based
Sodium Based
Calcium Based with EP Additives
Inhibitors & Zinc Oxide Additives
Greases Not Recommended
Type of Grease Description
Cup Grease Light Service Calcium or Sodium Based Grease
Graphite Filled Greases with More than 10% Graphite
Molybdenum Filled Greases with More than 10% Molybdenum Disulfide
Fluorocarbon Low Molecular Weight Chlorofluoroethylene Polymer
with Inert Thickeners
White Grease Calcium Based, Zinc Oxide Filled
Chapter 4 - Specifications
• Standard in-cab manual controls which allow for precise
metering of the manual hydraulic valve. Solenoid-activated
hydraulic control valve with electric remote control pendant
is optional.
• Ten (10) gallon capacity frame-mounted oil reservoir.
• Hydraulic flow shall not exceed 16-gallons per minute.
• Patented dump/load interface on double pivot models.
• Hydraulic locks to prevent cylinder movement in case of
pressure loss.
• Grease zerks at all points to allow purging of contaminates.
• Mechanical rear body tie-down latches.
• Resettable dump/tilt tabs.
11Specifications 11
• Hydraulic rotary valve to prevent front tilt movement when
the dump frame is raised.
• DX pre-lubricated bushings used at pivot points.
• Greaseable load rollers.
60-8 84-10 108-12 120-14
Lifting/Dumping Capacity Up to 9,000lbs
(4,082kg) (7,257kg) (7,257kg) (7,257kg)
A Dump Angle 54° 53° 54° 50°
B Lowest Hook Heigh 23.5” (60cm) 25” (63.5cm) 27” (68.5cm) 28” (71cm)
fective Length
Ef
C
D Truck Frame Height 34” (86cm) 36” (91.5cm) 36” (91.5cm) 36” (91.5cm)
E Hooklift Height 39.5” (100cm) 41.5” (105.5cm) 41.5” (105.5cm) 41.5” (105.5cm)
Hooklift Length 99.25” (252cm) 126” (320cm) 154” (391cm) 161” (409cm)
G
H Hooklift Center of Gravity 43” (109cm) 58” (147cm) 68” (173cm) 70” (178cm)
I Chassis Cab to Axle 60” (152.5cm) 84”-96” 108”-120” 120”-130”
J Max. Height When Loading 104” (264cm) 118” (300cm) 135” (343cm) 136” (345.5cm)
K Longest Body to Dump 120” (305cm) 144” (366cm) 180” (457cm) 192” (488cm)
L Max. Height When Dumping 141” (358cm) 162” (411.5cm) 185” (470cm) 187” (475cm)
Operating Pressure See table 1.1 See table 1.1 See table 1.1 See table 1.1
Shipping Weight 1,275lbs (578.5kg) 1,360lbs (617kg) 1,615lbs (733kg) 1,650lbs (748.5kg)
Hook Height
(from bottom of hook bar)
Shipping Dimensions 100”x49”x47” 126”x49”x47” 154”x49”x47” 161”x49”x47”
(LxHxW) (254x124.5x119.5cm) (320x124.5x119.5cm) (391x124.5x119.5cm) (409x124.5x119.5cm)
91” (231cm) 115” (292cm) 142” (361cm) 151” (383.5cm)
35.63” (90.5cm)
Up to 16,000lbs
(213.5cm-244cm)
35.63” (90.5cm)
Up to 16,000lbs Up to 16,000lbs
(274.5cm-305cm)
35.63” (90.5cm)
(305cm-330cm)
35.63” (90.5cm)
12 Flex36 Owner’s Manual
Stellar Flex36 Model 60-8 Hydraulic Hooklift Specifications
ifting Capacity: Check table 1.1 for variable lifting capabilities.
L
ontainer Length: 8-foot through 9-foot. Longer bodies up to 10-feet may be accommodated if full dump angle is not required (may require
C
pecial body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier
s
afety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).
S
ody length does not include A-frame.
B
Maximum Dump Angle: 54°
Operating Pressure: See table 1.1 in Chapter 6: Installation for variable pressure settings.
Weight of Hooklift: Hooklift weight not to exceed 1,275 pounds.
Height of Hooklift: Hooklift height not to exceed 5.5" as measured from top of truck frame to top of hooklift rollers.
Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body
10-inches below grade, when mounted on a 34” truck frame height.
Hydraulic Pump: Direct-coupled high-pressure gear pump.
Hydraulic Contro
ontrols: D
C
Tilting Hook Assembly: Hooklift must have pivoting type front tilt section (jib) to provide a low degree loading/unloading angle and also to provide
Tilt Cylinder: Cylinder must be double acting (4” Bore x 2” Rod x 17” Stroke) and include dual integral pilot-operated counterbalance
Tilt Section Operation: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is in the dumping
Lift/Dump Cylinder: Cylinder must be double acting and include dual pilot-operated counterbalance valves to prevent cylinder movement in
Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 25” wide frame to
Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift through all ranges of
Rear Dump Hinge Pin: 2-inch diameter type 304 or 17-4 stainless steel minimum.
l Valve: Hydraulic valve mounted directly onto the oil reservoir with power beyond capabilities.
ual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all hooklift functions.
a wider stance for side to side stability.
valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to
prevent exposure of cylinder rod to corrosive road salts.
mode.
case of pressure loss.
provide support for the container while in the dump mode. These sections form this frame without the use of mechanical
latches which rely on gravity, springs, or container/body mounted latches. The system must be protected from out of
sequence operation.
the dump mode. This must be accomplished without the use of steel springs and/or hydraulic/air cylinders.
Pins:
Bushings:
Hoses & Hyd. Fittings: All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.
Electrical: All electrical wiring to be protected by full length steel conduit fastened into the hooklift framework.
Technical Documentation: All hooklifts shall come with documentation on operation, maintenance, safety and a parts manual.
Regulations: Hooklift shall be designed and manufactured to all local, state and federal regulations.
Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.
All pins to be type 304 or 17-4 stainless steel.
All bushings to be of the DX pr
in heavy containment and corrosive environments.
ed steel hydraulic tubing to be used whenever possible.
Secur
e-lubricated variety, used with grease fittings. Bronze bushings not allowed due to survivability
Specifications 13
Stellar Flex36 Model 84-10 Hydraulic Hooklift Specifications
ifting Capacity: Check table 1.1 for variable lifting capabilities.
L
ontainer Length: 10-foot through 12-foot. Longer bodies up to 13-feet may be accommodated if full dump angle is not required (may require
C
pecial body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety
s
dministration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134). Body
A
ength does not include A-frame.
l
Maximum Dump Angle: 53°
Operating Pressure: See table 1.1 in Chapter 6: Installation for variable pressure settings.
Weight of Hooklift: Hooklift weight not to exceed 1,360 pounds.
Height of Hooklift: Hooklift height not to exceed 5.5" as measured from top of truck frame to top of hooklift rollers.
Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body
10-inches below grade, when mounted on a 36” truck frame height.
Hydraulic Pump: Direct-coupled high-pressure gear pump.
Hydraulic Contro
ontrols: D
C
Tilting Hook Assembly: Hooklift must have pivoting type front tilt section (jib) to provide a low degree loading/unloading angle and also to provide a
Tilt Cylinder: Cylinder must be double acting (4” Bore x 2” Rod x 17” Stroke) and include dual integral pilot-operated counterbalance
Tilt Section Operation: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is in the dumping mode.
Lift/Dump Cylinder: Cylinder must be double acting and include dual pilot-operated counterbalance valves to prevent cylinder movement in
Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 25” wide frame to
Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift through all ranges of
Rear Dump Hinge Pin: 2-inch diameter type 304 or 17-4 stainless steel minimum.
Pins: All pins to be type 304 or 17-4 stainless steel.
l Valve: Hydraulic valve mounted directly onto the oil reservoir with power beyond capabilities.
ual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all hooklift functions.
wider stance for side to side stability.
valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to pre-
vent exposure of cylinder rod to corrosive road salts.
case of pressure loss.
provide support for the container while in the dump mode. These sections form this frame without the use of mechanical
latches which rely on gravity, springs, or container/body mounted latches. The system must be protected from out of
sequence operation.
the dump mode. This must be accomplished without the use of steel springs and/or hydraulic/air cylinders.
Bushings: All bushings to be of the DX pre-lubricated variety, used with grease fittings. Bronze bushings not allowed due to survivability in
heavy containment and corr
Hoses & Hyd. Fittings: All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.
Secured steel hydraulic tubing to be used whenever possible.
Electrical:
Technical Documentation: All hooklifts shall come with documentation on operation, maintenance, safety and a parts manual.
Regulations:
Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.
All electrical wiring to be protected by full length steel conduit fastened into the hooklift framework.
Hooklift shall be designed and manufactured to all local, state and federal regulations.
osive envir
onments.
14 Flex36 Owner’s Manual
Stellar Flex36 Model 108-12 Hydraulic Hooklift Specifications
ifting Capacity: Check table 1.1 for variable lifting capabilities.
L
ontainer Length: 12-foot through 14-foot. Longer bodies up to 16-feet may be accommodated if full dump angle is not required (may require
C
pecial body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety
s
dministration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134). Body
A
ength does not include A-frame.
l
Maximum Dump Angle: 54°
Operating Pressure: See table 1.1 in Chapter 6: Installation for variable pressure settings.
Weight of Hooklift: Hooklift weight not to exceed 1,615 pounds.
Height of Hooklift: Hooklift height not to exceed 5.5" as measured from top of truck frame to top of hooklift rollers.
Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body
10-inches below grade, when mounted on a 36” truck frame height.
Hydraulic Pump: Direct-coupled high-pressure gear pump.
Hydraulic Contro
ontrols: D
C
Tilting Hook Assembly: Hooklift must have pivoting type front tilt section (jib) to provide a low degree loading/unloading angle and also to provide a
Tilt Cylinder: Cylinder must be double acting (4” Bore x 2” Rod x 17” Stroke) and include dual integral pilot-operated counterbalance
Tilt Section Operation: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is in the dumping mode.
Lift/Dump Cylinder: Cylinder must be double acting and include dual pilot-operated counterbalance valves to prevent cylinder movement in
Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 25” wide frame to
Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift through all ranges of
Rear Dump Hinge Pin: 2-inch diameter type 304 or 17-4 stainless steel minimum.
Pins: All pins to be type 304 or 17-4 stainless steel.
l Valve: Hydraulic valve mounted directly onto the oil reservoir with power beyond capabilities.
ual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all hooklift functions.
wider stance for side to side stability.
valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to pre-
vent exposure of cylinder rod to corrosive road salts.
case of pressure loss.
provide support for the container while in the dump mode. These sections form this frame without the use of mechanical
latches which rely on gravity, springs, or container/body mounted latches. The system must be protected from out of
sequence operation.
the dump mode. This must be accomplished without the use of steel springs and/or hydraulic/air cylinders.
Bushings: All bushings to be of the DX pre-lubricated variety, used with grease fittings. Bronze bushings not allowed due to survivability in
heavy containment and corr
Hoses & Hyd. Fittings: All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.
Secured steel hydraulic tubing to be used whenever possible.
Electrical:
Technical Documentation: All hooklifts shall come with documentation on operation, maintenance, safety and a parts manual.
Regulations:
Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.
All electrical wiring to be protected by full length steel conduit fastened into the hooklift framework.
Hooklift shall be designed and manufactured to all local, state and federal regulations.
osive envir
onments.
Specifications 15
Stellar Flex36 Model 120-14 Hydraulic Hooklift Specifications
ifting Capacity: Check table 1.1 for variable lifting capabilities.
L
ontainer Length: 13-foot through 15-foot. Longer bodies up to 16-feet may be accommodated if full dump angle is not required (may require
C
pecial body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety
s
dministration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134). Body
A
ength does not include A-frame.
l
Maximum Dump Angle: 50°
Operating Pressure: See table 1.1 in Chapter 6: Installation for variable pressure settings.
Weight of Hooklift: Hooklift weight not to exceed 1,650 pounds.
Height of Hooklift: Hooklift height not to exceed 5.5" as measured from top of truck frame to top of hooklift rollers.
Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body
10-inches below grade, when mounted on a 36” truck frame height.
Hydraulic Pump: Direct-coupled high-pressure gear pump.
Hydraulic Contro
ontrols: D
C
Tilting Hook Assembly: Hooklift must have pivoting type front tilt section (jib) to provide a low degree loading/unloading angle and also to provide a
Tilt Cylinder: Cylinder must be double acting (4” Bore x 2” Rod x 17” Stroke) and include dual integral pilot-operated counterbalance
Tilt Section Operation: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is in the dumping mode.
Lift/Dump Cylinder: Cylinder must be double acting and include dual pilot-operated counterbalance valves to prevent cylinder movement in
Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 25” wide frame to
Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift through all ranges of
Rear Dump Hinge Pin: 2-inch diameter type 304 or 17-4 stainless steel minimum.
Pins: All pins to be type 304 or 17-4 stainless steel.
l Valve: Hydraulic valve mounted directly onto the oil reservoir with power beyond capabilities.
ual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all hooklift functions.
wider stance for side to side stability.
valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to pre-
vent exposure of cylinder rod to corrosive road salts.
case of pressure loss.
provide support for the container while in the dump mode. These sections form this frame without the use of mechanical
latches which rely on gravity, springs, or container/body mounted latches. The system must be protected from out of
sequence operation.
the dump mode. This must be accomplished without the use of steel springs and/or hydraulic/air cylinders.
Bushings: All bushings to be of the DX pre-lubricated variety, used with grease fittings. Bronze bushings not allowed due to survivability in
heavy containment and corr
Hoses & Hyd. Fittings: All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.
Secured steel hydraulic tubing to be used whenever possible.
Electrical:
Technical Documentation: All hooklifts shall come with documentation on operation, maintenance, safety and a parts manual.
Regulations:
Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.
All electrical wiring to be protected by full length steel conduit fastened into the hooklift framework.
Hooklift shall be designed and manufactured to all local, state and federal regulations.
osive envir
onments.
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